This Week's Top Stories
Use Ergonomics To Improve Safety
During design always consider ease of construction and use. Read more...
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Regulation: Tiny Particles Get Big Attention
Federal, state, international regulations target nanoscale materials. Read more...
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Inexpensive Catalyst Generates Hydrogen From Water
Material boasts high activity and stability even in dirty or salt water. Read more...
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2010 Powder Show -- Product-Focus Series: Inpro/Seal
Reporting from the 2010 Powder & Bulk Solids Show, Senior Digital Editor Traci Purdum learns about the Air Mizer and its many applications. Read more...
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Webcast: CFATS Timeline & Latest Regulatory Updates
This on-demand event explores timelines, regulatory and legislative updates and Site Security Plans. Read more...
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How do you rate your site's interest in wireless technology?
Take the anonymous poll now to benchmark against your peers. Read more...
What Your Peers Are Reading
- Compressed Air Systems: The Secret is in the PipeThere’s no such thing as too large a compressed air line. A common error in compressed air systems is line sizes too small for the desired air flow.
- Don't Underestimate Overfilling's Risks High level can pose serious hazards but seven simple steps can prevent them.
- How Much do Chemical Engineers Make? Chemical Processing Reveals all in 2008 Salary SurveyIs it a tragedy or comedy for engineers? Survey results peak behind the curtain of readers' salaries and job satisfaction
- Comical Processing: You Write The Cartoon CaptionChemical Processing introduces "Comical Processing," featuring drawings by award-winning cartoonist Jerry King.
- Assessing Pressure Relief NeedsEvaluating thermal expansion and overpressure protection.
Just Posted
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Prepare for More Safety Inspections
A recently launched enforcement program targets chemical facilities.
Don't Underestimate Overfilling's Risks
High level can pose serious hazards but seven simple steps can prevent them.
Industry News More »
Vendor News More »
Ask the Experts More »
Chemical Security Action BlogMore »
Chemical Reaction BlogMore »
New Products
Benchtop Dissolved Oxygen Meter Can Test Biological Samples
Simulation Software Supports Rotor Stator Dispersers
Automated Overfill Protection Reduces Potential Hazards
New Control Station Features Can Help Reduce Data-Entry Errors
Plasma Simulation Module Available For Wide Range Of Industries
New Dust-Collector Filter Is Designed To Save Energy
Flexible I/O Capabilities Can Simplify Model Selection
Quality Management Solution Includes Graphical Workflow Displays
Critical Topics
Reducing energy consumption and your plant's environmental impact is a hot topic. Creative thinking in your energy efficiency projects will give you the competitive edge during these tough times.
Drive up energy efficiency
The constant-speed approach to AC motors made a lot of sense when energy was cheap and drives technology was in its infancy. With their latest advances, adjustable speed drives can provide one of the best energy efficiency options for a plant.
Consider Three Ways to Energy Efficiency
Now’s the time to make radical changes in funding energy projects
It’s time for a design check
Pay closer attention to energy efficiency and impose standards.
Special Report: Energy Efficiency
Reducing energy consumption and your plant’s environmental impact is a hot topic. In this Special Report we take a look at the organizational obstacles to avoid, how to enroll your employees in the quest, and the steps you need to take in order to manage your energy costs. We also delve in to practical energy efficient applications such as recovering exhaust heat in air conditioned facilities and the use of carbon synchronous belts.
Energy Savings Pick up Steam
More attention to steam systems and trap monitoring provides big benefits. At most chemical plants, plant management and operators face increasing pressures to improve the energy efficiency of their processes, so they should see how they can save on steam.
You can't manage what you can't measure. And what you don't measure will never improve. Enter plant optimization. Gathering data to improve operations offers a competitive advantage.
Avoid Costly Design Mistakes
Common errors keep plants from getting the most reliable and suitable vessels
Avoid costly materials mistakes
Common oversights keep plants from getting the most reliable and suitable vessels.
Avoid costly fabrication mistakes
Common oversights keep plants from getting the most reliable and suitable vessels
Pursue the perfect plant
Look into creating the “perfect plant” by integrating product and operational management into your environment. This provides the ability to respond faster and minimize impact to the business and bottom line, driving increased yields, asset utilization and order fulfillment.
Pilot plants: destined for development
Pilot plants are on the verge of an unprecedented evolution. Read about the 10 factors that'll impact the design, construction and operation of these next-generation units.
The chemical industry is starting to unwrap the potential benefits of “going green."
Renewable Feedstocks are in the Bag
Chemical firms show growing interest in bio-based production.
Environmental Protection
Environmental Protection by Dave Russell, president, Global Environmental Operations Inc.
Chemical industry sees green
Developments target economics, not just environmental benefits. While pollution prevention was the original goal of green chemistry, today’s efforts promise to have a substantial economic impact.
Special Report: Chemical Industry Sees Green | Bio-Based Fuels and Feedstocks
For years the industry has been “talking green.” But what real strides have been made? Will a Presidential Executive Order compel the industry to speed up efforts to actually go green?
Defining "Green Chemicals"
As the Industrial Water Treatment Program Manager at the federal installation, I am interested in resorting to "green chemicals" in the chemically treating all the boilers, cooling towers and closed loop systems at this installation. Is there a clear definition of what constitutes "green chemicals?" Does that vary from state-to-state, region-to-region, and who has the final word on what is or isn't "green chemicals?"
Feedstock change is hot and poppin’
Corn, other renewable resources garner increasing interest and investment. Read here about the progress that is being made in discovering a new generation of feedstock.
Wastewater treatment is a critical process for chemical plants. Keeping on top of how to recycle and reuse will ensure you get the most of your water-treatment operations.
Act Before There’s Not a Drop to Drink
Ground water protection is the responsibility of everyone including the chemical industry. An energetic group of state and federal ground water agencies, industry, environmentalists and other stakeholders, however, has made it a key area of their focus. The Ground Water Protection Council (GWPC) is a nonprofit Section 501(c)(6) organization dedicated to promoting and ensuring the use of best management practices and “fair but effective” laws regarding comprehensive groundwater protection.
Expect More Water Regulation Everywhere
EPA gets tough on arsenic levels in drinking water
What’s on tap for water?
This increasingly precious resource is attracting more attention
Better water technology is on tap
The drought in many parts of the U.S. so far this summer points out the preciousness of water supplies. There’s greater demand for waste-minimization and recycle-and-reuse technologies as well as more awareness of utility usage and the impact of life-cycle costs on water-treatment operations. Here’s a look at new technologies that will help.
Optimize Water Use
Four major drivers are spurring increasing interest in optimizing water use.
Boosting worker performance benefits the bottom line. Understanding what operators need is critical to your site's success.
Operators Get More Help
Efforts aim to provide insights and tools to boost performance.
Fitting the Workplace to the Worker
Process Industry Control Rooms Would Be Designed a Whole Lot Differently if Air-Traffic Controllers Were Working in Them
Operator Performance Takes Center Stage
Industry/university alliance aims to address human factors in process control.
Help Your Operators
Automating procedures within control systems can serve to make your operators more effective and more consistent. With studies showing more than 40% of all plant incidents stemming from some form of human error, it makes sense to give automation a larger role in day-to-day operations.
An Alert Operator Is a Safe Operator
Maintaining a good work environment can contribute to a safer plant
More Topics:
- Automation & IT
- Compressors
- Control Systems
- Design & Simulation
- Distillation
- Drying
- Environmental, Health & Safety
- Filtration
- Fluid Handling
- Instrumentation
- Powder & Solids
- Pumps
- Reaction & Synthesis
- Reliability & Maintenance
- Security
- Separations Technology
- Software
- Utilities & Energy
- Valves
- Wireless
White Paper Library
- Automation & IT
- Design & Simulation
- Environmental, Health & Safety
- Fluid Handling
- Powder & Solids
- Reaction & Synthesis
- Reliability & Maintenance
- Security
- Separations Technology
- Utilities & Energy
Automation & IT
Get Smarter And Faster With Integrated Supply Chain Planning
Supply Chain Planning and Forecasting coupled with a process ERP solution is the perfect fit to synch sales and marketing with manufacturing and supply chain operations. "Best Practices in Demand Planning" shows you how this integrated solution can reduce forecast errors, increase plant throughput, and reduce inventory levels.
Staying Competitive in the Changing Chemical Manufacturing Marketplace
Positioned at the core of most supply chains, chemical firms must deal with many challenges to growing profitably -- flat demand, deflationary prices, and emerging competitors to name a few. Both chemicals firms large and small must develop the insight to change and win in today's ever-morphing competitive landscape. This white paper identifies and discusses how chemicals companies can combine data from many sources -- multiple ERP systems, multiple divisions and multiple applications -- maintenance, human capital, CRM, and supply chain to name just a few -- to create a complete or holistic view for critical decisions. Download now.
Design & Simulation
ChemicalProcessing Special Report: Pilot Plants
Read about the 10 factors that will impact the design, construction and operation of these next-generation pilot plant units.
Learn about new pilot plant development methods.
Understand the role operational guidance plays in successful pilot plant development.
Design and Rating Shell and Tube Heat Exchangers
This 30-page paper discusses the basic design, construction and performance of shell and tube heat exchangers.
Environmental, Health & Safety
Asking The Right Questions About Cartridge Dust Collection
Over the past decade, cartridge-style dust collectors have overtaken baghouses as the preferred technology for dust collection in the chemical processing industry. Combining high efficiency filtration with compact size and reduced pressure drop, a high efficiency cartridge dust collector will in most cases be the system of choice.
Choosing the best cartridge collection system for a given application, however, involves research and attention to detail. This article will review four key areas of investigation. By reviewing these topics with a knowledgeable equipment supplier and knowing the right questions to ask, chemical manufacturing professionals will be better equipped to make informed dust collection decisions. Download this whitepaper now.
The Green Solution
The ever present emphasis on technological efficiency is just one of several forces behind the pressure on companies to "go green" despite a trying economy. The ultimate criterion that determines whether a motor is truly green is energy efficiency. Technology, long the key to efficiency, can help resolve this issue.
Fluid Handling
Spray Gas Quench Design Considerations
The use of spray nozzles to rapidly cool or quench gas streams is an essential application in many industrial processes, such as chemical reaction vessels, incineration, and power plant absorber gas inlet. An optimized spray quench design requires engineering analysis of the operating environment, spray nozzle performance and process reliability. This technical paper describes the design considerations for spray gas quench systems such as nozzle selection, process control, system configuration and reliability. Application of this knowledge can result in a gas quench system that operates efficiently and reliably with reduced vessel size, reduced atomization energy consumption, and minimized downtime, to achieve capital and operational cost savings for your process.
Peristaltic Pumps: A Simple Solution for Abrasive and Corrosive Chemicals
Finding the right pump for metering abrasive and aggressive chemicals can be challenging. The pump of choice needs to withstand harsh chemicals, accurately meter, and be simple to maintain and operate. More and more process engineers are turning to peristaltic pumps to solve their pumping problems, reducing life cycle costs and driving gains in process efficiency.
Powder & Solids
Asking The Right Questions About Cartridge Dust Collection
Over the past decade, cartridge-style dust collectors have overtaken baghouses as the preferred technology for dust collection in the chemical processing industry. Combining high efficiency filtration with compact size and reduced pressure drop, a high efficiency cartridge dust collector will in most cases be the system of choice.
Choosing the best cartridge collection system for a given application, however, involves research and attention to detail. This article will review four key areas of investigation. By reviewing these topics with a knowledgeable equipment supplier and knowing the right questions to ask, chemical manufacturing professionals will be better equipped to make informed dust collection decisions. Download this whitepaper now.
How Well Do You Know Your Dust?
The collection and testing of dust samples is a long-established practice used by many powder and bulk processors to make informed dust collection decisions. Dust testing protocols have not changed markedly in recent years. The importance of dust testing, however, has changed, and the implications are significant. While knowing your dust has always been good practice, it is rapidly becoming a necessity in today's regulatory climate.
This article will review two separate types of testing: (1) explosibility testing, which is used to determine whether a dust is combustible; and (2) bench testing, which pinpoints numerous physical properties of the dust. Both categories of tests are needed to determine the best dust collection system for your application and whether explosion venting equipment must be part of that system.
Reaction & Synthesis
Properly Model and Control Batch Reactors
This paper covers key aspects for modeling and design of batch reactors, including: heat-up and cool-down performance, sensitivity analysis for reactor parameters, boil-up rate predictions, thermal stability under exothermic conditions, control system design and loop tuning parameters, condenser rating, and process emissions predictions.
Maximize Returns from Precious-Metal-Bearing Catalysts
Many catalytic reactions rely on platinum, palladium and other precious metal catalysts. When the activity of the catalyst declines to the point that it must be replaced, the used catalyst can be sent to a refiner to recover precious metal. This 8-page paper discusses the variouis factors that should be considered when using a refiner.
Reliability & Maintenance
Continuous Valve Monitoring for Product Loss Prevention, Emission Reduction and ROI
One of the challenges that companies have faced in implementation of continuous monitoring systems is the lack of infrastructure for sensing and data collection. The devices to be monitored are widely dispersed throughout plants with large areas, have no existing power or signal transmitting wire infrastructure, so the capital costs associated with the power and communication services have historically prohibited continuous monitoring. This white paper will unearth best practices to prevent product loss, reduce emissions and ensure ROI.
SPECIAL REPORT: Condition Monitoring
An exciting trend in the world of CMMS is the increasing sophistication of condition-based maintenance (CBM) features and functions vendors offer and maintenance professionals actually use. This Special Report covers:
* Six steps to condition-based maintenance
* Bolster your condition monitoring toolbox
* Protect your condition-monitoring program from the recession guillotine
* Go beyond condition monitoring
Security
White Paper: Ten Tips for Completing a Site Security Plan
Working on your Site Security Plan (SSP)? The next stage in the Chemical Facility Anti-Terrorism Standards (CFATS) compliance process requires covered facilities to submit a SSP. Given the importance of the SSP, covered facilities should address a number of factors while they complete this step in the CFATS regulation. Download this complimentary whitepaper now: Ten Tips for Completing your SSP.
Process Safety Symposium – Making Safety Second Nature
This 10-page document discusses how the reference from the Center for Chemical Process Safety -- "Inherently Safer Chemical Processes, A Life Cycle Approach," 1st Edition, 1996 -- was updated in 2007. Inherent Safety has been well received by industry, but there has been significant advancement in the concept of inherently safer design over the last 10 years. This overview highlights lessons learned and best practices in inherent safety.
Separations Technology
Continuous Pressure and Vacuum Filtration and Washing of Organic Cellulose and Biomass Products
Organic cellulose and biomass filtration, washing and drying is very unpredictable and even minor differences in feedstock,washing or cake moisture requirements can require a different process solution. Both vacuum and pressure operations can provide equivalvent process results. On-site testing is required to determine the optimum filter selection.
A Review of Filter Press Basics and Issues
Filtration experts, over the years, have discussed filter presses and have indicated that soon they would be a thing of the past; the last filter press would be replaced by more modern equipment. This article discusses the perceived shortcomings of the filter press as well as the batch or continuous filtration alternatives to replace them.
Utilities & Energy
Chemical Processing Special Report: Compressed Air
Chemical manufacturers today are looking at all aspects of their business to conserve energy and decrease costs. Compressed air is often over looked in these efforts as many people do not fully understand compressed air equipment, their own system, or what it costs to produce compressed air power. In this Special Report, we review compressed air and provide insights on how to understand equipment and identify potential areas for savings.
The Green Solution
The ever present emphasis on technological efficiency is just one of several forces behind the pressure on companies to "go green" despite a trying economy. The ultimate criterion that determines whether a motor is truly green is energy efficiency. Technology, long the key to efficiency, can help resolve this issue.
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Video & Audio
Rosenzweig's Ramblings November 2009: Take a Safe Approach to Safety Equipment
Chemical Processing's Editor-in-Chief urges readers to not risk finding out whether bargains really will work right.
Rosenzweig's Ramblings October 2009: Industry Safety Initiative Deserves Applause
Chemical Processing's Editor-in-Chief notes that the American Chemistry Council is moving proactively to influence legislation.
Rosenzweig's Ramblings December 2009: Grasp All the Lessons of Bhopal
Chemical Processing's Editor-in-Chief is worried that industry still hasn't adequately addressed one factor behind the disaster.
Perspectives
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Chemical Processing Online
Get Ready for A Metamorphosis
A milestone birthday means changes all around.
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Compliance Advisor
Transportation Revisions Are Coming Down the Pipeline
Possible changes to rules for transporting combustible materials may eliminate confusion.
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End Point
Chemical Engineers Aim to Help Parliament
Fellowship program should enhance analysis of science and technology issues.
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Energy Saver
Energy Saver -- Educate Your Peers
Train your technical specialist on energy efficiency.
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Field Notes
Size Pumps Like a Pro
Use a step-by-step process to avoid pitfalls.
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From the Editor
Look on the Positive Side Of The Oil Spill
The Gulf of Mexico disaster may prompt some welcome developments.
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Plant InSites
Rethink Reactor Temperature Control
Cascade strategy offers simplicity and fast response.
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Process Puzzler
Successfully Satisfy Catalyst Requirements
Readers recommend ways to remove excess oxygen and water.
Ask the Experts
We've assembled a roster of leading authorities in many fields to help you address technical issues. Pose a question or browse previous questions to find the answers you're looking for.
Recent Mixing question...
Q:I have a tank that is 5 meters diameter and 7.5 meters tall. The bottom is flat. The liquid is water. The solid is small metal oxide particles very easy to suspend. Settling time is more than minutes. Would like to build a mixer for suspension only (not vigorous mixing).
Question: 1. What mixer diameter do I need? 2. What RPM? 3. What shaft diameter needed? 4. What HP do I need? 5. Do I need bottom shaft support and bearing?
Editors' Corner
Like Us On Facebook
In addition to great posts and fun topics, Chemical Processing fans also get to take part in contests to win accolades from their peers – and sometimes even great prizes!
Be sure to visit the Chemical Processing Magazine
Facebook page and "Like" us . . . we'll promise to make it worth the effort!
Traci Purdum, Senior Digital Editor
tpurdum@putman.net.
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Vital Resources
Webcast: CFATS Timeline & Latest Regulatory Updates
Watch this on-demand event to find out about the current and pending legislative impact on manufacturing, storage and the use of Chemicals of Interest (COIs) - plus practical advice for compliance. Also, learn about important legislative updates from the Society of Chemical Manufacturing & Affiliates (SOCMA).
Webcast: Best Practices In Inventory Optimization And Supply Chain Planning
With multiple, interlinked supply chains - each with a mix of raw materials, production, packaging, and distribution stages - companies have to keep even the simplest calculations up to date. This webcast will examine how Eastman Chemical Co. is facing these challenges.
Powder Show 2010 -- Product-Focus Series: Fike
Reporting from the 2010 Powder & Bulk Solids Show, Senior Digital Editor Traci Purdum learns more about explosion protection and why it's a top-of-mind topic. She also gets a sneak peek at Fike's newest product -- EPIC.
Introducing The Chemical Security Action Blog
Safety and security at chemical plants is imperative. To help chemical facilities better understand threats, implement best practices and talk about what's at risk, we have brought on guest blogger Ryan Loughin, director of Petrochemical & Energy Solutions for the Advanced Integration division of ADT.
Chemical Processing Special Report: Compressed Air
In this Special Report, we review compressed air and provide insights on how to understand equipment and identify potential areas for savings.
Take Part In CP Panel Discussions
Our Panel Discussion Series will gather experts to address important trends that will impact your chemical facility. As a registered audience member, you can ask questions during these 60-minute webcasts. See what discussions we have planned.
How Automated Water Jetting Improves Tube Bundle Cleaning Efficiency
Heat exchanger efficiency is a critical factor in processing productivity, and tube bundles must be kept clear of deposits to maintain that efficiency. Automated high-pressure water jetting systems, with flexible or rigid lances, remove deposits 75% to 90% faster than manual methods and are more operator-friendly.
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